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Need help "gasless" MIG welding

Discussion in 'Builds and Fabricators Forum' started by Big Burro, Jan 10, 2005.

  1. Jan 10, 2005
    Big Burro

    Big Burro New Member

    Corona, California
    Joined:
    Dec 10, 2004
    Messages:
    16
    This goes to all you welders out there. I just got a new MIG welder and can't seem to get it right. I can get a pretty good bead. Good penetration through the 1/4" plate that I'm using but I've got spater EVERYWHERE. It makes the finished product look like crap.

    Anyone out there proficient with the "gasless" MIG welding technique? I could sure use some pointers. I'm wondering if it might not be the voltage setting thats too high but I'd be guessing. If I fill up with shielding gas would that alone eliminate the spatter?

    Any help I could get is greatly appreciated.
     
  2. Jan 10, 2005
    JohnyJeep

    JohnyJeep BLOWING A XING NEAR U@2AM Sponsor

    Beautiful Cody WY
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    Sep 22, 2002
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    From the limited experience I have with flux core wire (and i'm no expert), it just plain sux. You really can't get a good clean weld with it. Gas IMO is the best way to go. You may still get little BB's here and there, but nothing like flux core.
    Does your welder have adaptability for gas?
     
  3. Jan 10, 2005
    screwcity

    screwcity New Member

    Colorado springs, Co
    Joined:
    Dec 16, 2004
    Messages:
    46
    if you are getting too much splatter it seems to me that you are "high arcing" try turning up the speed on the wire feed and it'll keep the wire/arc closer to the metal, and there will be less of a chance that the arc will jump around on you.....

    Rio
     
  4. Jan 10, 2005
    Boyink

    Boyink Super Moderator Staff Member Sponsor

    Ava, MO
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    Sep 20, 2002
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    I used one roll of the flux core/gasless setup in my welder before converting it...and I think it's just how gasless works. After I converted to "real" MIG it was much cleaner.
     
  5. Jan 10, 2005
    Old Bill

    Old Bill Aggressively passive....

    Really Southern...
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    Nov 12, 2004
    Messages:
    822
    I found that with flux core, I had to go fairly slow, less than half the full speed. (around 3.5~4 out of 10.) I was welding some 1/4" and 3/16", even some 3/8". I had some splatter, but it either brushed off with the wire brush, or cleaned up easily with a fast pass of the 50 grit sanding disc on the small angle grinder. Nothing I had to *really* grind off.
    But keep in mind, I got one of the "Dual Mig" setups from Harbour Freight, so not a real high end unit. YMMV.

    You may also try a different brand of wire. I had to replace my roll with a different brand, same type, and it made a pretty notable difference. For the better that is.

    What kind of welder ar you using? You may see about backing down a notch on the heat if you have one with plenty of juice. Worth a trial on some scrap anyway.

    Otherwise, practice, practice, practice.
     
  6. Jan 10, 2005
    Hawk62cj5

    Hawk62cj5 Captain of OldSchool Sponsor

    Brodnax Va.
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    Oct 28, 2004
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    696
    try to make to switch to gas , as far as quality of the welds go youll never regret it.
     
  7. Jan 10, 2005
    speedbuggy

    speedbuggy Looking for a Jeep now Sponsor

    Living the Good...
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    I use a flux core and it is ok for what I do. I've found that a little wd-40 on the surrounding areas helps in wiping off the splatter. Yes, it would be nice to have the gas there, but it works just fine the way it is.
     
  8. Jan 10, 2005
    Big Burro

    Big Burro New Member

    Corona, California
    Joined:
    Dec 10, 2004
    Messages:
    16
    I can convert to gas pretty easily since my unit will handle both. I just tried to cut a corner with the flux core. I was thinking about the WD-40 trick too. I know that you can use "lube Gel" to protect the surrounding area but, of course, I don't have any. I think I'll try making a few more test welds using different settings and, if that fails, I'll have the tank filled and try that.

    Thanks for your input and I'll let you guys know how it goes.
     
  9. Jan 10, 2005
    MNTrailboss

    MNTrailboss Member

    Minneapolis, MN
    Joined:
    Nov 10, 2003
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    104
    Make sure your steel is absolutely clean before welding as well. Wiping it off with a rag doesn't count.

    That will help a bit with spatter, but mostly with weld integrity.
     
  10. Jan 11, 2005
    lynn

    lynn Time machine / Early CJ5 HR Rep Staff Member Sponsor

    Huntingdon PA
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    Sep 20, 2002
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    3,449
    I've been reading this thread...
    I have a little Lincoln unit that welds flux-core wire... gasless.
    I get lots of spatter, and the welds simply aren't as good as I made years ago with a similar Hobart unit that was set up for gas.
    Last year I bought the conversion kit to switch my little Lincoln Weld Pak 100 over to gas. But then I balked at the price of a bottle. :rofl: So I never converted the welder, I still struggled along with the flux core junk.

    Well after deciding that this Saturday I'm going to tackle my frame repair, and reading this thread...
    I'm going to get a bottle of 75/25 tonight or tomorrow night. Probably get a 40 cu/ft bottle. Then I'll install the conversion kit on the welder before I start removing the bumper/fuel tank on Saturday in preparation for the repair.

    Thanks for providing the incentive guys. I know it will be worthwhile. :)
     
  11. Jan 11, 2005
    Boyink

    Boyink Super Moderator Staff Member Sponsor

    Ava, MO
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    Thats the welder I have Lynn - you'll love the true MIG setup!
     
  12. Jan 11, 2005
    Warloch

    Warloch Did you say Flattie??? Staff Member Sponsor

    Falcon, CO
    Joined:
    Mar 4, 2003
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    I have a Millermatic 175 - my first new welder since the 70's - been using the Flux Core. No problem with splatter other than retraining my hand to stop moving down while welding. Speed and arc length seems to be the key here.

    Just got the gas for it - so I could weld body metal - seems alot cleaner, but have only used it on 18G so far.
     
  13. Jan 11, 2005
    vanguard

    vanguard Guest

  14. Jan 11, 2005
    Boyink

    Boyink Super Moderator Staff Member Sponsor

    Ava, MO
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    You got a welder and you ordered a cart? :? :) :D
     
  15. Jan 11, 2005
    Tumbleweed

    Tumbleweed Senior member

    Boise, Idaho
    Joined:
    Sep 27, 2002
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    764
    Get a spray can of anti-splattter stuff from your welding supply store-it does make a difference.
     
  16. Jan 12, 2005
    vanguard

    vanguard Guest

    I couldn't buy the materials for the price of the cart. :sad: I looked.
     
  17. Jan 12, 2005
    MNTrailboss

    MNTrailboss Member

    Minneapolis, MN
    Joined:
    Nov 10, 2003
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    104
    The bottle price is a drag, but how you buy gas varies around the country, I guess. Used to be able to rent a bottle, but my local guy won't do that unless I'm a commercial customer. So I dropped about $75.00 for a small bottle (don't remember the size off hand, but it's only about 2 feet high). I went through 1.5 tanks completely restoring the jeep -- fixing the frame, creating rocker rails, building mounting brackets, fixing windshields, new bumper, etc. Point is that refilling the tank was only $15.00. But I had to exchange my nice new 'purty' tank for a used one and all the new paint was scratched off :cry:
     
  18. Jan 12, 2005
    vanguard

    vanguard Guest

    I think the bottles are about $75 for a lifetime lease here and about $20-$30 for the gas depending on the mix.
     
  19. Jan 12, 2005
    Boyink

    Boyink Super Moderator Staff Member Sponsor

    Ava, MO
    Joined:
    Sep 20, 2002
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    Same here. Also learned to not get attached to a specific bottle..;)
     
  20. Jan 12, 2005
    lynn

    lynn Time machine / Early CJ5 HR Rep Staff Member Sponsor

    Huntingdon PA
    Joined:
    Sep 20, 2002
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    3,449
    I got the bottle last night. It's a 2 ft. tall bottle, 40 cubic feet. For this size bottle my local welding supply only services "customer owned" bottles. Only the larger bottles are leased. So I bought the bottle for $88. Then the gas, tax, etc, total was $121 and change. Refills will be $27 for 75/25, and I understand about not getting attached to my specific bottle ;)

    So now I need to install the conversion kit on the machine and try it out. I'll need to practice a bit, so the first project is to weld up an angle iron bracket and attach it to the cart to keep the bottle secure.

    EDIT: I just looked at that cart Joel posted from HF... :shock: looks better than what I had in mind ! $29.99 + $7.99 s/h... hard to beat that... unless you have Boyink's cart :D
     

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